Noise dampening energy efficient tape and gasket material

ABSTRACT

A noise dampening tape and gasket material for reducing or preventing unwanted electromagnetic interference from escaping or entering an enclosure. The noise dampening gasket includes an inner core section, a carbon material layer surrounding the inner core section, an insulating layer surrounding the carbon material layer, and a metal shield layer surrounding the insulating layer. The noise dampening tape includes a metal shield layer, an insulating layer adjacent to and in contact with the metal shield layer, a carbon material layer adjacent to and in contact with the insulating layer, and an adhesive layer disposed on a surface of the carbon material layer. A second adhesive layer can be disposed on a surface of the metal shield layer. The carbon fibers can be coated with silicone or polytetrafluoroethylene to enhance mechanical and electrical properties of the carbon material layer.

CROSS REFERENCE TO RELATED APPLICATIONS

This application is a division of copending U.S. application Ser. No.14/194,473, filed Feb. 28, 2014, which is a continuation-in-part of U.S.application Ser. No. 13/172,694, filed Jun. 29, 2011, now U.S. Pat. No.8,692,137, issued Apr. 8, 2014, and which is a continuation-in-part ofcopending U.S. application Ser. No. 13/431,746, filed Mar. 27, 2012,which is a continuation-in-part of Ser. No. 13/039,981, filed Mar. 3,2011, now U.S. Pat. No. 8,164,527, issued Apr. 24, 2012, allincorporated by reference herein.

TECHNICAL FIELD

This disclosure relates to electromagnetic noise dampening materials,and, more particularly, to noise dampening energy efficient tape andgasket material.

BACKGROUND

Electromagnetic noise can escape or otherwise be emitted fromenclosures, which can interfere with electronic circuits or otherdevices nearby. Signals transmitted over electrical cables or throughthe air can be impacted, even severely disrupted, by the electromagneticemissions. Most enclosures have edges, seams, openings, physicalinterfaces, and the like, through which the electromagnetic noise canescape. The types of enclosures that can cause such issues includepersonal computers, computer server equipment, broadcast equipment,sensitive satellite control devices, cellular tower equipment, handhelddevices, and indeed, any enclosure that surrounds or contains electricalcomponents such as circuit elements, conductors, or the like.

In some cases, it is desirable to prevent electromagnetic radiation ornoise originating from external sources from penetrating the enclosurethrough similar edges, seams, openings, interfaces, and the like, whichcan otherwise cause unwanted interference with circuits and othercomponents located within the enclosure. This can be of particularconcern with test chambers or other similar types of test equipment andenclosures.

Government agencies such as the Federal Communications Commission (FCC),among other private and public bodies, require the adherence to exactingstandards for the emission of electromagnetic radiation. Much effort isexpended in complying with the various laws and rules governing suchemissions. Compliance through testing, redesigns, certifications, andthe like, quite often requires the devotion of significant resources andtime by product developers.

Conventional techniques for addressing these problems includeredesigning the enclosure to reduce the number of places in which theelectromagnetic energy escapes and/or enters the enclosure. Othertypical approaches include covering the seams and openings using sheetmetal. Still other approaches require arduous testing after eachiteration of enclosure redesign, leading to further enclosure redesigns.Efforts to address the consequences of unwanted electromagnetic noiseunfortunately can lead to less efficient designs. For instance, theenergy efficiency of the system can become a concern because oneapproach for overcoming unwanted electromagnetic interference is toboost the power of the signals themselves to compensate for the noise.Such approaches lead to energy waste and are environmentally unwise.

Accordingly, a need remains for a noise dampening energy efficient tapeand gasket material for reducing unwanted electromagnetic interferencebetween enclosures and devices external to the enclosures. In addition,it would be desirable to have a more energy efficient and cost effectivesolution for addressing leakage of electromagnetic noise to and fromenclosures. Embodiments of the invention address these and otherlimitations in the prior art.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1A illustrates a perspective view of an example of a noisedampening energy efficient circuit gasket according to an embodiment ofthe present invention.

FIG. 1B illustrates a plan view of the noise dampening energy efficientgasket of FIG. 1A.

FIG. 2A illustrates a perspective view of another example of a noisedampening energy efficient circuit gasket according to anotherembodiment of the present invention.

FIG. 2B illustrates a plan view of the noise dampening energy efficientgasket of FIG. 2A.

FIG. 3 illustrates a plan view of an enclosure having the noisedampening gasket of FIGS. 1A and 1B fitted thereto.

FIG. 4 illustrates a plan view of an enclosure having the noisedampening gasket of FIGS. 2A and 2B fitted thereto.

FIG. 5 illustrates a side elevation view of the enclosure of FIG. 4having the noise dampening gasket of FIGS. 2A and 2B fitted thereto.

FIG. 6A illustrates a cross sectional view of a noise dampening energyefficient tape according to another example embodiment of the presentinvention

FIG. 6B illustrates a perspective view of the noise dampening energyefficient tape of FIG. 6A.

FIG. 7A illustrates a cross sectional view of a noise dampening energyefficient tape according to another example embodiment of the presentinvention.

FIG. 7B illustrates a perspective view of the noise dampening energyefficient tape of FIG. 7A.

FIG. 8 illustrates a plan view of an enclosure having the noisedampening tape applied thereto along a seam.

FIG. 9 illustrates a plan view of an enclosure having the noisedampening tape applied thereto around a physical interface.

FIG. 10 illustrates a perspective view of an enclosure having the noisedampening tape applied to edges thereof.

FIG. 11 illustrates a cross sectional view of a multi-directional noisedampening energy efficient tape according to yet another exampleembodiment of the present invention.

FIGS. 12A and 12B illustrate acceptable fabric structures andconstruction for the carbon fiber layer.

FIGS. 12C, 12D and 12E show Z-axis structures for the carbon fibermaterial.

FIG. 12F shows processes for making Z-axis carbon fiber materials.

FIG. 13 illustrates cross-sectional views of examples of single andmultilayer fabrics incorporating a treated carbon fiber layer andconductive layer/fabric (FIGS. 13A and 13B) and an untreated carbonfiber layer (FIGS. 13C and 13D) with a dielectric layer between thecarbon fiber layer and the conductive layer/fabric.

The foregoing and other features of the invention will become morereadily apparent from the following detailed description, which proceedswith reference to the accompanying drawings.

DETAILED DESCRIPTION

Embodiments of the invention include noise dampening energy efficienttape and gaskets, and associated materials and components. The terms“electromagnetic noise” or “interference” as used herein generally referto unwanted electromagnetic waves or signals having the potential todisrupt the operation of electronic equipment or other devices. Itshould be understood, however, that the embodiments disclosed herein canprovide beneficial electromagnetic wave dampening for any type ofelectromagnetic signal, whether or not it is considered “noise” per se,and whether or not actual disruption is caused, and therefore, suchterms should be construed broadly.

FIG. 1A illustrates a perspective view of an example of a noisedampening energy efficient circuit gasket 100 according to an embodimentof the present invention. FIG. 1B illustrates a plan view of the noisedampening gasket 100 of FIG. 1A. Reference is now made to FIGS. 1A and1B.

The noise dampening gasket 100 includes an inner core section 110, acarbon material layer 125 surrounding the inner core section 110, aninsulating layer 120 surrounding the carbon material layer 125, and ametal shield layer 115 surrounding the insulating layer 120. In someembodiments, an outer insulating and protective film 130 covers themetal shield layer 115.

The carbon material layer 125 is preferably up to one (1) millimeter inthickness, although thicker layers can be used. In some embodiments, thecarbon material layer 125 can include resin-impregnated woven carbonfiber fabric. In a preferred embodiment, the resin-impregnated carbonmaterial has a specific resistance no greater than 100 Ω/cm². In someembodiments, the carbon material layer 110 includes carbon nanotubematerial.

The carbon material layer 110 can include strands of carbon fiberrunning along a length of the gasket 100, for example, in parallelrelative to an axial direction of the inner core section 110. In someembodiments, substantially all of the fiber strands of the carbonmaterial layer 125 are disposed in parallel relative to the axialdirection of the inner core section 110.

Alternatively, the strands of carbon fiber may run circumferentiallyaround the gasket 100 relative to the inner core section 110. In yetanother configuration, the multiple layers of strands of carbon fibercan be disposed one atop another, and/or woven, with each layer havingthe carbon strands orientated at a different angle respective to oneanother. For example, one layer of strands can be orientated at 90degrees relative to another adjacent layer.

In some embodiments, the carbon material layer 125 includes a firstlayer having fiber strands orientated in a first direction atsubstantially 45 degrees relative to an axial direction of the innercore section 110, and a second layer having fiber strands orientated ina second direction crossing the fiber strands of the first layer atsubstantially 45 degrees relative to the axial direction of the innercore section 110.

In this manner, electrons can travel along certain paths or patterns inthe carbon material layer, allowing the electromagnetic noisecharacteristics of the environment to be controlled. It should beunderstood that a weave pattern can be designed to include other formsor patterns depending on the qualities and noise characteristics of aparticular circuit or enclosure with which the gasket 100 is used.

The metal shield layer 115 can be a flexible conducting metal layer,including for example, copper (Cu), but can include any suitableconductor including gold (Au), silver (Ag), and so forth. The inner coresection 110 is formed from either a solid pliable shape of conducting ornon-conducting material. The insulating layer 120 is preferably glassfiber material, but any suitable dielectric insulating material can beused.

The metal shield layer 115, the insulating layer 120, and the carbonmaterial layer 125 form an electromagnetic dampening zone 135surrounding the inner core section 110 in which the carbon materiallayer 125 enhances the shielding characteristics of the metal shieldlayer 115. The positioning of the carbon material layer 125 with respectto the metal shield layer 115, separated by the insulating layer 120,enhances the metal shield layer operation of dampening electromagneticnoise.

The carbon material layer 125 can directly contact the inner coresection 110. Similarly, the metal shield layer 115 can directly contactthe insulating layer 120. In addition, the insulating layer 120 candirectly contact the carbon material layer 125. It should be understoodthat while the perspective view of the gasket 100 in FIG. 1 A showsdifferent layer protruding from the gasket, the layers of the gasket canbe flush so that the gasket 100 is formed in a substantially cylindricalembodiment. It should also be understood that the cross sectional shapeof the gasket 100 need not be cylindrical, but can be formed in othershapes such as rectangular, triangular, hexagonal, and so forth.

FIG. 2A illustrates a perspective view of another example of a noisedampening energy efficient circuit gasket 200 according to anotherembodiment of the present invention. FIG. 2B illustrates a plan view ofthe noise dampening gasket 200 of FIG. 2A. Reference is now made toFIGS. 2A and 2B.

The noise dampening gasket 200 includes an inner core section 210, acarbon material layer 225 surrounding the inner core section 210, aninsulating layer 220 surrounding the carbon material layer 225, and ametal shield layer 215 surrounding the insulating layer 220. In someembodiments, an outer insulating and protective film 230 covers themetal shield layer 215. The inner core section 210 includes acylindrical opening 230 therein extending through the gasket.

The composition, dimensions, and characteristics of the components ofgasket 200 are similar to or the same as those described above withreference to gasket 100, and so an abbreviated description is includedwith reference to gasket 200. The primary difference is that the innercore section 210 includes the opening 230 therein for receiving aconductor or other type of wire or cable.

In similar fashion, the metal shield layer 215, the insulating layer220, and the carbon material layer 225 form an electromagnetic dampeningzone 235 surrounding the inner core section 210 in which the carbonmaterial layer 225 enhances the shielding characteristics of the metalshield layer 215, thereby reducing or preventing unwantedelectromagnetic interference.

FIG. 3 illustrates a plan view of an enclosure 300 having the noisedampening gasket 100 of FIGS. 1A and 1B fitted thereto. The enclosure300 may include walls that form a container for sensitive electronicssuch as circuits components, conductors, or the like. An opening orinterface 305 can be disposed in a wall of the enclosure 300, and thenoise dampening gasket 100 can permanently or temporarily “plug” theopening. FIG. 3 illustrates the gasket 100 inserted in the opening 305of the wall of the enclosure 300 so that electromagnetic noise isreduced or otherwise prevented from escaping or entering the enclosure300.

FIG. 4 illustrates a plan view of an enclosure 400 having the noisedampening gasket 200 of FIGS. 2A and 2B fitted thereto. FIG. 5illustrates a side elevation view of the enclosure 400 of FIG. 4 havingthe noise dampening gasket 200 of FIGS. 2A and 2B fitted thereto.Reference is now made to FIGS. 4 and 5.

The enclosure 400 may include walls that form a container for sensitiveelectronics such as circuit components, conductors, or the like. Anopening or interface 405 can be disposed in a wall of the enclosure 400,and the noise dampening gasket 400 can permanently or temporarily “plug”the opening. FIG. 4 illustrates the gasket 200 inserted in the opening405 of the wall of the enclosure 400 so that electromagnetic noise isreduced or otherwise prevented from escaping or entering the enclosure400.

Moreover, a conductor 410 such as a wire or cable can be disposed withinthe opening 230 of the inner core section 210 of the gasket 200 so thatdevices or components contained within the enclosure 400 can interfacewith devices, power sources, or other components located external to theenclosure 400. The electromagnetic dampening zone 235 is structured toreduce electromagnetic noise emitted by the conductor 410. In addition,the gasket 200 is structured to prevent electromagnetic noise fromescaping or entering the enclosure 400.

FIG. 6A illustrates a cross sectional view of a noise dampening energyefficient tape 600 according to another example embodiment of thepresent invention. FIG. 6B illustrates a perspective view of the noisedampening tape 600 of FIG. 6A. Reference is now made to FIGS. 6A and 6B.

The noise dampening tape 600 includes a metal shield layer 615, aninsulating layer 620 adjacent to and in contact with the metal shieldlayer 615, a carbon material layer 610 adjacent to and in contact withthe insulating layer 620, and an adhesive layer 625 disposed on asurface of the carbon material layer 610.

The carbon material layer 610 is preferably up to one (1) millimeter inthickness, although thicker layers can be used. In some embodiments, thecarbon material layer 610 can include resin-impregnated woven carbonfiber fabric. In a preferred embodiment, the resin-impregnated carbonmaterial has a specific resistance no greater than 100 Ω/cm². In someembodiments, the carbon material layer 610 includes carbon nanotubematerial.

The carbon material layer 610 can include strands of carbon fiberrunning along a length of the tape 600, for example, in parallelrelative to the lengthwise direction 640. In some embodiments,substantially all of the fiber strands of the carbon material layer 610are disposed in parallel relative to the lengthwise direction 640 of thetape 600. The tape can be wound or otherwise disposed around core 645for easy storage, transporting and dispensing.

In some embodiments, the multiple layers of strands of carbon fiber canbe disposed one atop another, and/or woven, with each layer having thecarbon strands orientated at a different angle respective to oneanother. For example, one layer of strands can be orientated at 90degrees relative to another adjacent layer. In some embodiments, thecarbon material layer 610 includes a first layer having fiber strandsorientated in a first direction at substantially 45 degrees relative toa lengthwise direction 640 of the tape, and a second layer having fiberstrands orientated in a second direction crossing the fiber strands ofthe first layer at substantially 45 degrees relative to the lengthwisedirection 640 of the tape.

In this manner, electrons can travel along certain paths or patterns inthe carbon material layer, allowing the electromagnetic noisecharacteristics of the environment to be controlled. It should beunderstood that a weave pattern can be designed to include other formsor patterns depending on the qualities and noise characteristics of aparticular enclosure or surface with which the tape 600 is used.

The metal shield layer 615 can be a flexible conducting metal layer,including for example, copper (Cu), but can include any suitableconductor including gold (Au), silver (Ag), and so forth. The insulatinglayer 620 is preferably flexible glass fiber material, but any suitableflexible dielectric insulating material can be used.

The metal shield layer 615, the insulating layer 620, and the carbonmaterial layer 610 form an electromagnetic dampening zone 635 in whichthe carbon material layer 610 enhances the shielding characteristics ofthe metal shield layer 615. The positioning of the carbon material layer610 with respect to the metal shield layer 615, separated by theinsulating layer 620, enhances the metal shield layer operation ofdampening electromagnetic noise.

FIG. 7A illustrates a cross sectional view of a noise dampening energyefficient tape 700 according to another example embodiment of thepresent invention. FIG. 7B illustrates a perspective view of the noisedampening tape 700 of FIG. 7A. Reference is now made to FIGS. 7A and 7B.

The noise dampening tape 700 includes a metal shield layer 715, aninsulating layer 720 adjacent to and in contact with the metal shieldlayer 715, a carbon material layer 710 adjacent to and in contact withthe insulating layer 720, and an adhesive layer 725 disposed on asurface of the carbon material layer 710. In addition, the noisedampening tape 700 includes a second adhesive layer 723 disposed on asurface of the metal shield layer 715.

The composition, dimensions, and characteristics of the components ofnoise dampening tape 700 are similar to or the same as those describedabove with reference to noise dampening tape 600, and so an abbreviateddescription is included with reference to tape 700.

Electromagnetic noise can be prevented from escaping or entering anenclosure, or otherwise passing through a surface, depending on theorientation of the double adhesive tape 700. If it is desirable toprevent electromagnetic noise from escaping an enclosure, the tape 700is orientated so that the carbon material layer 710 is positioned towardthe inside of the enclosure, and the metal shield layer is positionedtoward the outside of the enclosure. If placed within the inside of theenclosure, one adhesive layer can be used to affix the tape in theproper orientation to the surfaces of the inside of the enclosure. Ifplaced outside of the enclosure, the other adhesive layer can be used toaffix the tape in the proper orientation to the surfaces of the outsideof the enclosure.

Conversely, if it is desirable to prevent electromagnetic noise fromentering the enclosure, the tape 700 is orientated so that the carbonmaterial layer 710 is positioned toward the outside of the enclosure,and the metal shield layer is positioned toward the inside of theenclosure. Since the tape 700 includes adhesive on both upper and lowersurfaces, positioning and attaching the tape is made simple for eitherorientation.

The metal shield layer 715, the insulating layer 720, and the carbonmaterial layer 710 form an electromagnetic dampening zone 735 in whichthe carbon material layer 710 enhances the shielding characteristics ofthe metal shield layer 715. The positioning of the carbon material layer710 with respect to the metal shield layer 715, separated by theinsulating layer 720, enhances the metal shield layer operation ofdampening electromagnetic noise.

FIG. 8 illustrates a plan view of an enclosure and/or surface 800 havingthe noise dampening tape 810 applied thereto along a seam. The noisedampening tape 810 corresponds to either the noise dampening tape 600 orthe noise dampening tape 700 described above. The enclosure 800 caninclude walls or surfaces in which a seam 805 is present. The noisedampening tape 810 can be disposed over the seam to reduce or preventelectromagnetic noise from passing through the seam. It should beunderstood that the noise dampening tape 810 can be disposed on eitherside of the seam 805. Moreover, the noise dampening tape 810 can bedisposed over the seam 805 of any surface, whether as part of theenclosure 800, or as a separate standalone surface. In other words, thenoise dampening tape 600 can cover one or more seams 805 associated withone or more surfaces 800.

FIG. 9 illustrates a plan view of an enclosure and/or surface 900 havingthe noise dampening tape 910 applied thereto around a physical device905 or interface. The noise dampening tape 910 corresponds to either thenoise dampening tape 600 or the noise dampening tape 700 describedabove. One or more openings or interfaces 920 may be disposed throughone or more surfaces 900. A physical component or device 905 can bedisposed in the one or more openings 920. The component 905 can be, forexample, a control panel, an input / output interface, a ventilationunit, an access panel, or the like. The noise dampening tape 910 can bedisposed on the one or more surfaces 900 around the component 905,and/or covering any cracks between the physical component 905 and theone or more openings 920.

FIG. 10 illustrates a perspective view of an enclosure 1000 having thenoise dampening tape 1010 applied to outside edges 1015 and inside edges1020 thereof The noise dampening tape 1010 corresponds to either thenoise dampening tape 600 or the noise dampening tape 700 describedabove. Edges of enclosures are often vulnerable to leakages due to thenature of the bends of the walls or the surface couplings, and cantherefore contribute to leaks in electromagnetic noise.

The noise dampening tape 1010 can be disposed on inside edges 1020 withthe carbon material layer orientated either toward the inside of theenclosure 1000 or toward the outside of the enclosure 1000. Moreover,the noise dampening tape 1010 can be disposed on outside edges 1015 withthe carbon material layer orientated either toward the inside of theenclosure 1000 or toward the outside of the enclosure 1000. When thecarbon material layer is orientated toward the inside of the enclosure,electromagnetic noise is contained within the enclosure and leakages arereduced or eliminated. Alternatively, when the carbon material layer isorientated toward the outside of the enclosure, electromagnetic noise isprevented from penetrating the enclosure.

FIG. 11 illustrates a cross sectional view of a multi-directional noisedampening energy efficient tape 1100 according to yet another exampleembodiment of the present invention.

The multi-directional noise dampening tape 1100 can dampenelectromagnetic noise irrespective of the direction in which theelectromagnetic waves are incident upon the tape. In other words, thenoise dampening tape can prevent or reduce electromagnetic noise orradiation from passing in either direction through the tape.

The multi-directional noise dampening tape 1100 includes a first metalshield layer 1115, a first insulating layer 1120 adjacent to and incontact with the first metal shield layer 1115, a carbon material layer1110 adjacent to and in contact with the first insulating layer 1120, asecond insulating layer 1130 adjacent to and in contact with the carbonmaterial layer 1110, and a second metal shield layer 1135 adjacent toand in contact with the second insulating layer 1130. In addition, thetape 1100 can include an adhesive layer 1123 disposed on a surface ofthe first metal shield layer 1115, and/or an adhesive layer 1125disposed on a surface of the second metal shield layer 1135.

Besides the difference in the number of layers in the tape, thecomposition, dimensions, and characteristics of the components of noisethe dampening tape 1100 are similar to or the same as those describedabove with reference to the noise dampening tapes 600 and 700, andtherefore, a detailed description is omitted for the sake of brevity. Itshould be understood, however, that the noise dampening tape 1100 can beused in conjunction with any of the embodiments or usages describedabove.

While some examples of noise dampening gasket and tape material typesand configurations are disclosed herein, persons with skill in the artwill recognize that the inventive concepts disclosed herein can beimplemented with a variety of different circuit gaskets, tapes,enclosures, shapes, and forms. The thickness of each of the variouslayers including the carbon material layer, the metal shield layers, theglass fiber material layers, and/or the insulating dielectric layers,can be, for example, up to one (1) millimeter in thickness, although inpractice, some layers are designed to be thicker than other layers, andcan be sized according to the expected frequencies at which signals areto be operated. For example, with higher frequency signals, thickerlayers can be used. Thus, higher frequency signals are supported in alower-noise environment. Further, each of the layers individually ortogether may have various degrees of flexibility or compressibility.

Power and energy efficiencies are also improved. For instance, as thenoise qualities of an enclosure are improved, the signal qualities alsoimprove, and the circuits and other components contained within theenclosure can operate with lower voltages, use fewer parts, less power,and so forth. Server farms use massive amounts of energy to operatemultiple circuit boards and other components, sometimes 24 hours perday, 365 days per year.

In other words, the power consumption characteristics and energyefficiencies associated with components operating within an enclosurecan be significantly improved, and can reduce these demands on theenergy infrastructure. Given that there are millions of enclosureshaving circuit boards and other devices contained therein, such powerand energy improvements can quickly multiply into significant reductionsin power usage, battery production and disposal, etc., thereby boostingconservations efforts worldwide.

Methods for construction the noise dampening gasket and tape are alsocontemplated as described herein. For example, a method for constructinga noise dampening gasket (e.g., 100/200) can include arranging aplurality of concentric layers, as described in detail above, one atopanother, around the inner core, and infusing epoxy into the carbonmaterial layer. A method for constructing the noise dampening tape caninclude forming the various layers, as described in detail above, oneatop another, and rolling or otherwise winding the layers around a corefor simple storage, transporting, and dispensing or other usage.

Individual carbon fibers or tows of carbon fibers form the carbon fiberlayer. The carbon fibers of the carbon fiber layer can be treated withsilicone to enhance their mechanical and electromagnetic properties. Thesilicone we have used is Polydimethylsiloxane in the form of MGChemicals Silicone Conformal Coating 422B. The silicone can be appliedby spray, brush, or immersion. The coating of silicone on the carbonfiber acts as an electrical insulating layer. The silicone treatedcarbon fibers lowers the electrical resistivity of the carbon fibers.

Alternatively, the carbon fibers of the carbon fiber layer can betreated with polytetrafluoroethylene to enhance their mechanical andelectromagnetic properties. The polytetrafluoroethylene (PTFE) we haveused is Teflon® manufactured by DuPont. The polytetrafluoroethylene canbe applied by spray, brush, immersion, and then sintering or compaction.The coating of polytetrafluoroethylene on the carbon fiber acts as anelectrical insulating layer. The polytetrafluoroethylene treated carbonfibers lower the electrical resistivity of the carbon fibers.

Untreated carbon fibers tend to be hydrophilic. Environmentalconditions, e.g. relative humidity and heat, can adversely affect theelectromagnetic and mechanical properties of untreated carbon fibers.Untreated carbon fibers are brittle and easily break, spall and fraywith handling or mechanical stress. Using the ASTM-D3217: 2007 StandardTest Method for Breaking Tenacity of Manufactured Textile Fibers in Loopor Knot Configurations, a 3 k tow of untreated carbon fibers wereover-hand knotted and subjected to increasing force until the knotbroke. The tow of untreated carbon fibers broke under less than 1 kg ofpull.

Silicone treated carbon fibers are hydrophobic. Silicone treated carbonfibers improve the stability of the mechanical, electromagnetic, andthermal properties over a range of environmental conditions. Siliconetreated carbon fibers are supple and bend without breaking undermechanical stress. Silicone treated carbon fibers are easy to mold anddo not break if mechanically stressed by sharp radius bends. Whensubjected to the same ASTM-D3217: 2007 Standard Test Method for BreakingTenacity of Manufactured Textile Fibers in Loop or Knot Configurations,a 3 k tow of silicone-treated carbon fibers demonstrated increasedmechanical strength. The tow broke under 6.1 kg of pull.

Likewise, polytetrafluoroethylene treated carbon fibers are hydrophobic.Polytetrafluoroethylene treated carbon fibers improve the stability ofthe mechanical, electromagnetic, and thermal properties over a range ofenvironmental conditions. Polytetrafluoroethylene treated carbon fibersare supple and bend without breaking under mechanical stress.Polytetrafluoroethylene treated carbon fibers are easy to mold and donot break if mechanically stressed by sharp radius bends. A 3 k tow ofpolytetrafluoroethylene treated carbon fibers was subjected to theASTM-D3217: 2007 Standard Test Method for Breaking Tenacity ofManufactured Textile Fibers in Loop or Knot Configurations. The tow ofpolytetrafluoroethylene treated carbon fibers was able to withstand moremechanical stress and broke at 7.1 kg of pull. Polytetrafluoroethylenetreated carbon fibers are also less bendable than silicone treatedcarbon fibers but more bendable than untreated carbon fibers. Further,polytetrafluoroethylene treated carbon fibers have more “memory” thanuntreated or silicone treated carbon fibers. In other words, apolytetrafluoroethylene treated carbon fabric may temporarily assume adifferent configuration when mechanical force is applied. However, thepolytetrafluoroethylene treated carbon fabric will return to itsoriginal shape once the force is removed. The step at which sintering orcompaction is applied to the polytetrafluoroethylene treated carbonfabric determines the original shape of the fabric.

Depending on the application, different fabric structures and alignmentscan be used to take advantage of the polarization properties of thecarbon fibers, as shown in FIGS. 12A-12G. For example, a simpleaxially-aligned fiber structure (FIG. 1) or helical fiber structure(FIG. 1) is useful to surround the inner core. For many applications, astandard over-under weave (FIG. 12A) or a twill woven pattern (FIG. 12B)suffices. Multiple aligned, non-woven layers can be laminated intransverse directions. In some situations, a circular or spiral basketweave can be useful. Another acceptable fabric structure is a braidformation. Further, a pile structure (FIG.12C) may be preferable to forma fabric with a Z-axis for radiation attenuation. A pile structureincludes a surface of upright strands, which may be uncut/looped (1204),cut (1208), or a mixture of cut and uncut strands (1206). The height ofthe strands may vary from 1 to 30 millimeters and may but are notrequired to be of uniform height.

As shown in FIG. 12C, the substrate (1202) in the fabric may be woven.Further, the materials forming the substrate (1202) may be conductive,insulative or a mixture of conductive and insulative materials.Embodiments of piled fabric include velvet, corduroy, and velveteen.

FIG. 12D depicts another perspective of the carbon fiber fabric (1210)assuming a pile structure with a Z-axis for radiation attenuation. Thecarbon fiber fabric (1210) may be composed of any one or more of thefollowing: insulative (dielectric) materials (1211), carbon fibers(1212), and metal strands (1214). An optional stabilizer or adhesivelayer (1218) may be attached to the carbon fiber fabric. The carbonfiber layer (1210) may be non-woven (1220) as shown in FIG. 12D. Oneembodiment of the unwoven carbon fiber fabric (1220) may be a mixture offree-standing materials, or in an alternative embodiment, the unwovencarbon fiber is a rigid matrix assembled by using the butcher blockmethod. The top layer of the butcher block may then to cut to form theZ-axis strands.

FIG. 12F depicts one embodiment of a method for forming woven carbonfiber fabric. At step 1222, a single, double-faced woven strand of anyone of the materials listed in FIG. 12D is formed by double warpweaving. The single strands formed at step 1222 are then joined togetherto form a mixture of insulation, metal, and/or carbon fibers at step1224. After step 1224, there are two methods to form the Z-axis strands.The pile may then be cut along the mid-line to yield two velvet surfaces(1226 and 1228). Alternatively, rails may be inserted into the top loopsduring the weaving process (1230). The rails can then be used as a loopcutting guide (1232). If loops are desired, the rails may simply beremoved (1234).

The carbon fiber layer can be incorporated into quilted fabrics withmultiple conductive layers as shown in FIGS. 13A-D. In such quiltedfabrics, the conductive layer can be made from a fabric woven withconductive threads. The quilt is layered and stitched together withnonconductive threads. The quilted fabric can also be vacuum formed withepoxy resins to form rigid structural materials.

The treated carbon fiber can be setup in laminates in which a treatedcarbon fiber layer is in direct contact with the metal layer, forexample, as shown in FIGS. 13A and 13B. The coating on the carbon fibersacts as thin dielectric layer that insulates the carbon fiber layer fromthe metal layer.

In FIGS. 13A-13D, like layers are denoted by like reference numerals.FIG. 13A shows what can be called a single layer carbon fiber compositewhich includes a conductive layer/fabric 1302 on a carbon fiber layer1304.The conductive layer/fabric can be formed of a metallic layer, or afabric that contains conductive threads, such as copper threads. Thecarbon fiber layer 1304 is formed by woven, non-woven, piled, braided,or aligned carbon fibers that have been treated with a suitable compoundthat makes the individual fibers insulative, such aspolydimethlylsiloxane or polytetrafluoroethylene (e.g., Teflon®). FIG.13B shows a multiple layer version of the structure of FIG. 13A, inwhich the treated carbon fiber layer 1304 is sandwiched between twolayers of the conductive layer/fabric 1302. FIG. 13C shows a singlelayer of untreated carbon fiber fabric 1308, similar to layer 1304 butnot silicone or polytetrafluoroethylene treated, with a contactingdielectric or insulative layer 1303 separating the carbon fiber fabric1308 from the conductive layer/fabric 1302 and 1306. FIG. 13D shows amultilayer version of the composite of FIG. 13C in which the untreatedcarbon fiber fabric 1308 is sandwiched between two layers of dielectric1303 and conductor 1302. These composite carbon fiber fabrics are usablein the noise dampening gasket or tape.

Consequently, in view of the wide variety of permutations to theembodiments described herein, this detailed description and accompanyingmaterial is intended to be illustrative only, and should not be taken aslimiting the scope of the invention.

1. A carbon fiber textile with enhanced mechanical and electromagneticproperties comprising: a plurality of carbon fibers aligned to form oneor more tows of the carbon fibers; a coating of polytetrafluoroethyleneon the carbon fibers which electrically insulates the carbon fibersindividually; the one or more tows of polytetrafluoroethylene-coatedcarbon fibers arranged to form a polytetrafluoroethylene-coated carbonfiber textile; the polytetrafluoroethylene-coated carbon fiber textilehaving a specific sheet resistance of the carbon fibers of less than orequal to 100 ohms per centimeter squared; and thepolytetrafluoroethylene-coated carbon fiber textile is resistant tobreakage and spalling of the individual carbon fibers.
 2. The carbonfiber textile of claim 1, wherein the polytetrafluoroethylene-coatedcarbon fiber textile has memory and returns to an original shape after amechanical force is removed.
 3. The carbon fiber textile of claim 1,wherein the specific resistivity is equal to or less than 1.0 ohms percentimeter squared along the aligned, polytetrafluoroethylene-coatedcarbon fibers.
 4. The carbon fiber textile of claim 1, wherein thepolytetrafluoroethylene-coated carbon fiber textile are less breakablethan untreated carbon fibers under mechanical stress.
 5. The carbonfiber textile of claim 4, wherein a 3 k tow ofpolytetrafluoroethylene-coated carbon fiber resists breakage at about 7kg of pull.
 6. The carbon fiber textile of claim 1, wherein thepolytetrafluoroethylene-coated carbon fibers are woven, non-woven,basket-woven, piled or aligned to form thepolytetrafluoroethylene-coated carbon fiber textile.
 7. The carbon fibertextile of claim 1, wherein the polytetrafluoroethylene-coated carbonfiber textile attenuates radio frequency electromagnetic radiation. 8.The carbon fiber textile of claim 1, wherein the enhanced mechanicalproperties comprise the ability to bend without breaking.
 9. A carbonfiber textile with enhanced mechanical and electromagnetic propertiescomprising: a plurality of carbon fibers aligned to form one or moretows of the carbon fibers; a coating of silicone on the carbon fiberswhich electrically insulates the carbon fibers individually; the one ormore tows of polytetrafluoroethylene-coated carbon fibers are arrangedto form a polytetrafluoroethylene-coated carbon fiber textile; and thepolytetrafluoroethylene-coated carbon fiber textile having sufficientresistivity of the aligned polytetrafluoroethylene-coated carbon fibersto attenuate radio frequency electromagnetic radiation.
 10. The carbonfiber textile of claim 9, wherein the polytetrafluoroethylene-coatedcarbon fiber textile is incorporated into a quilted textile.
 11. Thecarbon fiber textile of claim 10, wherein the quilted textile comprisesthe polytetrafluoroethylene-coated carbon fiber textile with at leastone conductive layer.
 12. The carbon fiber textile of claim 11, whereinthe conductive layer is comprised of a metallic layer.
 13. The carbonfiber textile of claim 11, wherein the conductive layer is comprised ofa textile containing conductive threads.
 14. The carbon fiber textile ofclaim 9, wherein the polytetrafluoroethylene-coated carbon fiber textileis arranged in a laminate with at least one metal layer.
 15. The carbonfiber textile of claim 9, wherein the polytetrafluoroethylene-coatedcarbon fiber textile is between at least two layers of conductivetextile.
 16. A method for forming a carbon fiber textile with enhancedelectromagnetic and mechanical properties, comprising: aligning aplurality of carbon fibers to form one or more tows of the carbonfibers; coating the carbon fibers with polytetrafluoroethylene whichelectrically insulates the carbon fibers individually; arranging one ormore tows of the polytetrafluoroethylene-coated carbon fibers to form apolytetrafluoroethylene-coated carbon fiber textile; and thepolytetrafluoroethylene-coated carbon fiber textile having sufficientresistivity of the aligned silicone-coated carbon fibers to attenuateradio frequency electromagnetic radiation.
 17. The method of claim 16,further comprising the polytetrafluoroethylene-coated carbon fibertextile having a specific sheet resistance of less than or equal to 1.0ohms per centimeter squared and an increased tolerance for bendingaround a radius.
 18. The method of claim 16, further comprising thepolytetrafluoroethylene-coated carbon fiber textile having a specificsheet resistance of 1.0 ohms per centimeter squared along the aligned,polytetrafluoroethylene-coated carbon fibers.
 19. The method of claim16, further comprising coating the carbon fibers withpolytetrafluoroethylene by at least one of the following methods: spray,brush, and immersion.
 20. The method of claim 19, further comprisingtreating polytetrafluoroethylene-coated carbon fibers by compaction orsintering.
 21. The method of claim 16, further comprising incorporatingthe polytetrafluoroethylene-coated carbon fiber textile into a quiltedtextile.
 22. The method of claim 16, further comprising joining thepolytetrafluoroethylene-coated carbon fiber textile to a conductivelayer.
 23. The carbon fiber textile of claim 16, further comprisingforming a laminate incorporating the polytetrafluoroethylene-coatedcarbon fiber textile.